Solder-bearing wafer for use in soldering operations

ABSTRACT

According to one embodiment, an electrical connector for electrical connection to a second electronic device having at least one second contact includes a substrate having a first surface and an opposing second surface, with a recess being formed in the first surface. The connect also has a first contact securely coupled to the substrate and having a first portion extending at least partially into the recess and a mass of solder material retainingly held in the recess such that the first portion of the first contact is in contact with the solder material. The first surface is for placement against the second electronic device such that the first and second contacts are aligned and whereupon heating of the mass of solder material, the first and second contacts are securely attached to one another and form an electrical pathway therebetween.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is continuation-in-part of U.S. patent application Ser. No. 10/982,986, filed Nov. 4, 2004, which is a continuation of U.S. patent application Ser. No. 10/019,507, filed Mar. 29, 2002, which is a U.S. national phase application under 35 U.S.C. §371 based upon International Application NO. PCT/US00/26160 filed Sep. 20, 2000, which claims the benefit of priority of U.S. Provisional Application Serial No. 60/154,771 filed Sep. 20, 1999. The entire disclosures of the prior applications are incorporated herein by reference. The international application was published in the English language on Mar. 29, 2001 under Publication No. W001/22785.

FIELD OF THE INVENTION

The present invention relates to the field of devices for joining connectors or other electrical components to one another and, more particularly, to a method and apparatus for facilitating the soldering of first electronic devices, such as connectors, to second electronic devices, such as printed circuit boards.

BACKGROUND OF THE INVENTION

It is often necessary and desirable to electrically connect one component to another component. For example, a multi-terminal component, such as a connector, is often electrically connected to a substrate, such as a printed circuit board, so that the terminals of the component are securely attached to contact pads formed on the substrate to provide an electrical connection therebetween. One preferred technique for securely attaching the component terminals to the contact pads is to use a solder material around a particular area, such as a hole, which typically receives one component terminal. Often, the component terminals may be in the form of conductive pins which are received within the holes formed in the substrate. The solder material, e.g., solder paste, is generally applied around each contact hole and then heated after the conductive pin is received within and extends through the contact hole. The heating of the solder paste causes the solder paste to flow around the conductive pin and the contact hole. The cooling of the solder paste results in the conductive pin being securely attached to one of the contact pads formed on the substrate.

While the use of solder paste is effective in some applications, there are a number of applications in which the use of solder paste is not desirable due to a number of factors, including but not limited to the design of both the component terminals and the substrate itself. In addition, the use of solder paste generally does not provide a sufficient volume of solder to properly join the component terminals and the contact pads.

One alternative approach to the use of solder paste is described in U.S. Pat. No. 5,875,546, which is assigned to the assignee hereof and which is incorporated by reference in its entirety. The device set forth in this reference comprises an array of solder-holding clips which is readily applied manually or by automation to a corresponding array of connector or other component terminals. The clips are typically formed by a die stamping operation which results in an increase in cost and complexity of the overall soldering operation.

It is therefore desirable to provide an alternative device and method for applying solder to connectors or the like.

SUMMARY

According to one embodiment, an electrical connector for electrical connection to a second electronic device having at least one second contact includes a substrate having a first surface and an opposing second surface, with a recess being formed in the first surface. The connect also has a first contact securely coupled to the substrate and having a first portion extending at least partially into the recess and a mass of solder material retainingly held in the recess such that the first portion of the first contact is in contact with the solder material. The first surface is for placement against the second electronic device such that the first and second contacts are aligned and whereupon heating of the mass of solder material, the first and second contacts are securely attached to one another and form an electrical pathway therebetween.

In yet another embodiment, a combination of electrical components includes an electrical connector and an electronic device. The connector includes a substrate having a first surface and an opposing second surface, with a recess being formed in the first surface. The connector also includes a first contact securely coupled to the substrate and having a first portion extending at least partially into the recess; and a mass of solder material retainingly held in the recess such that the first portion of the first contact is in contact with the solder material.

The combination also ha an electronic device having a second contact and a surface that faces the first surface of the substrate, the first and second contacts being aligned with one another and whereupon heating of the mass of solder material, the first and second contacts are securely attached to one another and form an electrical pathway therebetween

BRIEF DESCRIPTION OF THE DRAWINGS

Objects and features of the present invention will be described hereinafter in detail by way of certain preferred embodiments with reference to the accompanying drawings, in which;

FIG. 1 is a top perspective view of a wafer with pin holes located therethrough;

FIG. 2 is a side perspective view of the wafer of FIG. 1;

FIG. 3 is a top view of the wafer of FIG. 1 additionally having solder-holding grooves formed thereon;

FIG. 4 is a top view of the wafer of FHG. 3 additionally having through holes located therethrough;

FIG. 5 is a cross section view of the wafer of FIG. 4 taken along line 5-5;

FIG. 6 is a top view of the wafer of FIG. 5 wherein the solder-holding lengths have been partitioned;

FIG. 7 is a side view of the wafer of PIG. 6 having the pins of an electronic device placed through the respective pin holes of the wafer;

FIG. 8 is a bottom plan view of one exemplary electrical connector according to one embodiment of the present invention;

FIG. 9 is a top view of a wafer according to a second embodiment in which solder lengths are disposed within solder-holding grooves formed in the wafer;

FIG. 10 is a top plan view of the wafer of FIG. 9 wherein the solder lengths have been partitioned;

FIG. 11 is a side view of an assembly formed of a first electronic device coupled to a second electronic device with two wafers of FIG. 10 shown exploded therefrom;

FIG. 12 is a side view of the assembly of FIG. 11 with the two wafers being applied to a portion of the first electronic device;

FIG. 13 is a side view of the assembly of FIG. 12 showing the first electronic device soldered to the second electronic device and the two wafers having been removed from the assembly;

FIG. 14 is a side view of another exemplary wafer according to the present invention with solder lengths being provided on both sides thereof;

FIG. 15 is a side perspective view of a wafer according to another embodiment of the present invention;

FIG. 16 is a cross section view taken along the line 16-16 of FIG. 15;

FIG. 17 is a side elevation view of the wafer of FIG. 15 being used to electrically connect a first electronic device to a second electronic device;

FIG. 18 is a cross section side view of a connector according to another embodiment of the present invention;

FIG. 19 is cross section side view of a connector according to yet another embodiment of the present invention;

FIG. 20 is a side view of the connector of FIG. 19; and

FIG. 21 is cross section side view of the connector of FIG. 19 mated with a second electronic device.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In one aspect, the present invention facilitates the process of soldering electrical terminals or contacts of one electronic device to a surface of a second electronic device using a solder-bearing wafer. In one exemplary embodiment, the electrical contacts comprise conductive pins and the second electronic device comprises a printed circuit board. FIGS. 1 through 3 illustrate a method of forming a wafer according to a first embodiment of the present invention.

Turning to FIG. 1, a wafer 100 is provided and is formed of any number of suitable material and preferably is formed of a non-conductive material. For example, the wafer 100 may be formed of a thermoplastic material, thermoset plastic, etc. The wafer 100 has pin holes 110 formed therethrough. It will be appreciated that pin hole 10 does not necessarily have to have an annular shape and pin hole 10 generally comprises small holes formed in the wafer 10. The location and general spacing of pin holes 110 are determined by the location and spacing of pins of a first electronic device (FIG. 7) to be mounted onto a second electronic device, e.g., a printed circuit board (FIG. 7). It will therefore be appreciated that the pin holes 110 may be arranged according to any number of patterns depending upon the number of pin holes 110 and the location thereof. In the embodiment shown in FIG. 1, the pin holes 110 are arranged in horizontal rows along a first axis and vertical columns along a second axis and are spaced a predetermined distance apart from one another. The first axis extends generally across a length, L, of the wafer 100 and the second axis extends generally across a width, W, of the wafer 100. The first axis is thus preferably longer than the second axis. The pin holes 110, for example, are spaced a predetermined amount center-to-center along the first axis and a predetermined amount along the second axis to accommodate an electrical device having pins that are correspondingly spaced.

Furthermore, the length and width of the wafer 100 generally conform to the length and width of the first electronic device to be mounted onto the second electronic device. The depth or thickness of the wafer 100 is preferably about 0.030 inches. However, this measurement is merely for purpose of illustration.

The pin holes 110 may be formed through the wafer 100 using any of the methods known in the art, including, e.g., the use of a stamping die. Alternately, the pin holes 110 can be formed or molded during manufacture of the wafer 100.

Turning to FIG. 2, therein is illustrated a side perspective view of the wafer 100 where two pairs of the grooves 115 and 117 can be seen extending along the first axis of the wafer 100 on either side of each row of the pin holes 110. Although the grooves 115 and 117 are shown as having a half-cylindrical shape, it is understood that the shape of the grooves 115 and 117 may be any shape. Preferably, the shape of the grooves 115 and 117 conforms to the shape of a solder length 130 (FIG. 4) which, as will be described more fully below, is to be inserted in each of the grooves 115 and 117.

The grooves 115 and 117 are formed in the wafer 100 using any of the methods known in the art, including, e.g., the use of an etching or a stamping die. Alternately, the grooves 115 and 117 can be formed during manufacture of the wafer 100. For example, the grooves 115 and 117 may be used during a molding process which is used to manufacture the wafer 100. The grooves 115 and 117 may be formed on the wafer 100 before, during or after the placement of the pin holes 110.

Turning to FIG. 3, therein is illustrated the wafer 100 having the through holes 120 located therethrough along the first axis so that at least one through hole 120 is located on either side of each pin hole 110. As is shown, each through hole 120 extends sufficiently along the second axis to encompass one of grooves 115 and 117, respectively. The through holes 120 are formed on the wafer 100 using any of the methods described above for forming the pin holes 110 and the grooves 115 and 117.

According to the present invention, solder segments 135 are added to the wafer 100 for providing a solder material used to securely attach the first and second electronic devices to one another, as will be described hereinafter. FIGS. 4 through 6 illustrate the method of adding solder segments 135 to the wafer 100.

Turning to FIGS. 4, and 5 therein is illustrated the wafer 100 having solder lengths 130 placed in the grooves 115 and 117. The solder lengths 130 include any of the soldering compositions known in the art and are preferably shaped to be inserted form fittingly and securely within the grooves 115 and 117. In other words, the solder lengths 130 preferably comprise elongated strips of solder material which are shaped complementary to the grooves 115 and 117. Accordingly, in the present example, as particularly illustrated and shown in FIG. 5, the solder lengths 130 are cylindrically shaped so as to fit securely within the half-cylindrical shaped grooves 115 and 117 as in FIG. 2.

With continued reference to FIG. 4, it is shown that each pair of solder lengths 130 lies across a row of through holes 120. In this way, a press or stamp having dies shaped and spaced in conformance with the shape and position of through holes 120 on wafer 100 is used to sever solder lengths 130 at each of the through holes 120.

FIG. 6 illustrates the wafer 100 after the solder lengths 130 are severed as described above to form a plurality of solder segments 135. As is shown, each pin hole 110 has one solder segment 135 located on either side of the pin hole 110. Because each solder segment 135 is held securely by the groove 115 or 117, the wafer 100 can be held in any position required to conform to a particular manufacturing process or machinery being used (e.g., solder side facing-up, facing sideways, facing downward, etc.).

FIG. 7 illustrates an electronic device 150 having pins 140 extending from a first surface 151 thereof. The first electronic device 150 may comprise any number of suitable devices which are intended to be electrically connected to a second electronic device 160. For example and according to one exemplary embodiment, the first electronic device 150 comprises an electrical connector and the second electronic device 160 comprises a printed circuit board (through hole type device). The pins 140 comprise conductive pins which serve to establish an electrical connection between terminals (not shown) of the first electronic device 150 and corresponding electronic components of the second electronic device 160. The pins 140 are placed into respective pin holes 110 of the wafer 100. As shown in FIG. 7, the wafer 100 is positioned such that the solder segments 135 face downwards. Solder segments 135 are held in place by their form fitting interconnection with grooves 115 and 117.

Once the first electronic device 150 and the pins 140 have been inserted a sufficient distance into the wafer 100 and the pin holes 110, the side of the wafer 100 having solder segments 135 exposed may be placed onto the second electronic device 160 having pin holes 110 conforming to the spacing and size of the pin holes 110. The solder segments 135 are thereafter heated causing the solder segments 135 to reflow around the pins 140 and the pin holes 110 along with other surfaces of the second electronic device 160. As the solder segments 135 cool, the pins 140 are secured to the second electronic device 160 resulting in a secure electrical connection between the first and second electronic devices 150, 160. After the reheating and cooling of the solder segments 135, the wafer 100 remains soldered between the first electronic device 150 and the second electronic device 160. It being understood that the solder segments 135 are heated after the first and second electronic devices 150, 160 have been brought together.

Referring now to FIGS. 1 through 7. It will be appreciated that the provision of through holes 120 to permit the severing of solder lengths 130 also serves to define an amount of solder material around each of the pins 140. In other words, by providing two solder segments 135 adjacent to each of the pin holes 110, a defined amount of solder material is dedicated for the soldering of one pin 140 to a corresponding section of the second electronic device 160. The severing of the solder lengths 130 reduces the mass of solder material used in the solder operation which results in a decreased chance that a large soldered mass will result during the heating process. In addition, the severing of the solder lengths 130 also prevents adjacent contact sites from being starved. In other words, often the heating of contacts is not uniform and one contact (pin 140) will be heated greater and actually draws solder material from one or more adjacent sites. This causes the one or more adjacent contacts to be starved of the solder material and results in ineffective soldering of these contacts. By placing a defined amount of solder material around each pin 140, the solder material is effectively divided into local segments which are used for the soldering of one respective pin 140. Accordingly, the heating process produces distinctly spaced, soldered masses around the pins 140 rather than a single large soldered mass and the solder starvation sites associated with conventional techniques are eliminated.

The solder-bearing wafer 100 of the present invention overcomes many of the deficiencies associated with the devices of the prior art. First, the wafer 100 has a relatively simple yet effective design. Because the solder carrier medium is a thermoplastic material, conductive material will not remain attached to the contacts (pins 140) after the solder segments 135 reflow. Second, thermoplastic materials are typically less costly than the metal materials used to produce other soldering aid devices. Third, this results in reduced manufacturing costs and as simplicity of the present invention permits an operator to more easily and more quickly apply the wafer 100 to the first electronic device 150. Fourth, the wafer 100 also provides increased solder volumes by forming the solder segments 135 within the grooves 115 and 117 around the respective pins 140. This increase in solder volume provides more solder material for each solder joint formed between the devices 150, 160, thereby improving the quality of each of the solder joints. Fifth, the present invention provides tighter lead spacing in that the contacts (pins 140) of the first electronic device 150 may be closer together than would have been possible if other solder aides were used. Sixth, the solder-bearing wafer 100 permits irregular solder patterns to be formed thereon. This permits the soldering segments 135 to be formed on the wafer 100 at desired locations. Thus, the location of the solder segments 135 may be customized depending upon the specific application and depending upon the configuration of one or more of the first and second electronic devices 150, 160.

Different variations of the solder-bearing wafer 100 are possible depending on the particular application. For example, only a single solder length 130 and single groove may be provided for each row of pin holes. Also, fewer or greater than two rows of pin holes 110 may be provided on wafer 100. Also, the through holes 120 may not be necessary if the solder lengths 130 are segmented in a way which allows removal of the solder portions in between the desired segments, e.g., by way of a cutting and vacuum removal process. Further, the pin holes, through holes and grooves may take on any necessary shape depending on the particular application.

It will be appreciated that the wafer 100 may be distributed in a number of forms. For example, if the specifications of a given application are known, the wafer 100 may be cut to have a desired length and width so that the wafer 100 is disposed between the first and second electronic devices 150, 160 without the wafer 100 extending beyond either of the first or second electronic devices 150, 160. The wafer 100 may also be rolled onto reels and then distributed to a number of connector/electrical component manufacturers for retrofit to their existing or future products. The design of the wafer 100 therefore permits versatility in that it may not only be custom manufactured for one specific application but it also permits the wafer 100 to be distributed in a basic form and then retrofitted by the purchaser.

Now referring to FIG. 8 in which a first connector device according to a second embodiment of the present invention is illustrated and generally indicated at 200. The first connector device 200 is preferably an electrical connector which is designed to be electrically connected to another electronic device, such as the printed circuit board 160 shown in FIG. 7. The first connector device 200 is similar to the first electronic device 150 of FIG. 7 with the exception that the solder segments 135 are incorporated as part of the first connector device 200 rather than being provided on the wafer 100. In this embodiment, the wafer 100 is not used in the soldering of the first connector device 200 to the other electronic device.

As shown in FIG. 8, the first connector device 200 has a first surface 202 which faces the second electronic device when the two are soldered to one another. A plurality of pins 210 extend outwardly from the first connector device 200 and more specifically, the plurality of pins 210 extend away from the first surface 202. The plurality of pins 210 may be disposed across then first surface 202 according to any number of patterns and the row/column pattern shown in FIG. 8 is merely exemplary in nature. Furthermore, one will appreciate that the pins 140 may have any number of cross-sectional shapes and the circular cross-section shown is also merely exemplary.

According to the second embodiment, grooves 220 are formed across the first surface 202 similar to the first embodiment shown in FIGS. 1-7. The grooves 220 are designed to securely carry and locate solder material. In the exemplary embodiment, the grooves 220 extend horizontally across the first surface 202 with the grooves 220 being formed on either side of each row of pins 140. Similar to the first embodiment, the solder material is deposited as defined solder segments 135 into the grooves 220 formed in the first surface 202. Each pin 140 therefore has a solder segment 135 on one side thereof and another solder segment 135 on another side thereof. In one exemplary embodiment, the grooves 220 comprise a number of defined grooves 220 which extend along a common axis across the first surface 202. Each groove 220 therefore has a predetermined length and preferably all of the individual grooves 220 have the same length. The length of the grooves 220 will be determined by a number of factors including the size of the pins 140 and also the amount of the solder material which is to be deposited around the pin 140. It will be appreciated that in this embodiment, the grooves 220 are not in the form of single continuous grooves but rather comprise a number of spaced grooves 220 formed along a common axis with an ungrooved section 221 formed between adjacent grooves 220. The grooves 220 may be formed during the manufacture of the first connector device 200 or they may be formed by a subsequent operation, e.g., a stamping operation. Because the pins 140 act as conductive members, the first surface 202 of the first connector device 200 is preferably formed of a non-conductive material, such as a thermoplastic. This facilitates the formation of the grooves 220 as the grooves 220 may be formed in the first surface 202 during a molding process, or the like, which is used to form the first connector device 200.

After the grooves 220 are formed, the solder material is deposited therein so that a number of solder segments 135 are provided. The grooves 220 may be formed according to any number of known techniques. Each groove 220 defines one solder segment 135. As previously mentioned by forming two opposing grooves 220 around each pin 140, the amount of solder material for each pin 140 is generally defined as the amount of solder material being deposited within the two opposing grooves 220. By dividing the solder material into two distinct solder segments 135 around each pin 140, the likelihood that a single solid solder mass will result during reflowing of the solder material is reduced or eliminated as well as the presence of solder starvation sites is likewise eliminated. Advantageously, the use of solder segments 135 permits the proper amount of solder material to be delivered to each pin 140 for the soldering of the pin 140 to the other electronic device, such as a printed circuit board.

In this embodiment, the wafer 100 of FIG. 1 is not used but rather the solder holding features are incorporated directly into the design of the first connector device 200. This simplifies the soldering operation by eliminating the use of the intermediate wafer 100. Instead, the first connector device 200 is directly mated with another electronic device, e.g., a through-hole device, which receives the pins 140 and which are then soldered to the through hole devices. It will also be appreciated that while the first connector device 200 has been described in terms of containing pins 140, the device 200 may contain planar or other shaped contacts instead of pins 140. The solder segments 135 are simply disposed around these planar or other shaped contacts for providing a solder and electrical connection between each contact and the second electronic device.

FIGS. 9 through 10 illustrate a method of forming a wafer according to a second embodiment.

Turning to FIG. 9 in which a wafer according to a second embodiment of the present invention is illustrated and generally indicated at 300. The wafer 300 has a length, L, and a width, W. For purpose of illustration, only a section of the wafer 300 is shown in FIGS. 9 and 10. As in the first embodiment, the wafer 100 is formed of a non-conductive material, such as a suitable thermoplastic or thermoset material. The wafer 100 has a predetermined number of grooves, generally indicated at 310, formed in a first surface 302 of the wafer 300. In the exemplary embodiment, the grooves 310 comprise longitudinal grooves extending along the length L of the wafer 300. The cross-sectional shape of the grooves 310 may be any shape and in one exemplary embodiment, each groove 310 has a half-cylindrical cross-sectional shape. The grooves 310 are formed in the wafer 300 using any of the methods known in the art, including, e.g., the use of an etching or a stamping die. Alternatively, the grooves 310 can be formed or molded during the manufacture of the wafer 300.

The wafer 300 also includes a plurality of through holes 320 formed in the wafer 300. The through holes 320 are formed at spaced locations along each groove 310. In other words, through holes 320 are formed directly within the groove 310. As shown in FIG. 9, solder lengths 130 are placed within each of the grooves 310. Solder lengths 130 are preferably shaped to be inserted form fittingly and securely within the grooves 310. In the present example, the solder lengths 130 are cylindrically shaped so as to fit securely within the half-cylindrical shaped grooves 310. Each solder length 130 lies across a row of through holes 320. In this way, a press or stamp having dies shaped and spaced in conformance with the shape and position of the through holes 320 on the wafer 300 are used to sever solder lengths 130 at each of the through holes 320.

FIG. 10 illustrates the wafer 300 after the solder lengths 130 (FIG. 9) are severed as described above. As is shown, a number of spaced solder segments 135 are formed. More specifically, one solder segment 135 is formed on either side of one through hole 320. The solder segments 135 are still securely fit within the grooves 310 after the performing the operation to form the solder segments 135. The solder segments 135 are thus axially aligned in rows extending along the length of the wafer 300 with one through hole 320 being formed between next adjacent solder segments 135.

While FIG. 9 shows a pair of grooves 310 and solder lengths 130, it will be understood that the wafer 100 may contain a single groove 310 and solder length 130 or the wafer 100 may include more than two grooves 310 and solder lengths 130. Furthermore, while the wafer 300 shown in FIG. 10, has solder segments 135 formed in a staggered pattern, it will be understood that the solder segments 135 may be axially aligned with one another in columns as shown in FIG. 11.

The formation of through holes 320 within the wafer 300 and the subsequent severing of the solder length 130 to form the solder segments 135 serve to define the amount of solder material in each of the solder segments 135. By limiting the solder material to distinct solder segments 135, the likelihood that a single solid solder mass will result during reflowing of the solder material is reduced or eliminated. In contrast, each of the specific points of contact between the first and second electronic devices (not shown) may be provided with a predefined amount of solder material.

FIG. 11 is a partially exploded side view showing a first electronic device 330 and a second electronic device 340. One exemplary first electronic device 330 comprises a connector and more particularly, the illustrated first electronic device 330 comprises a connector which is commonly referred to as a straddle mount device. The device 330 has a base portion 332 and a plurality of contacts 334 extending therefrom. The contacts 334 serve to provide an electrical connection between the first electronic device 330 and the second electronic device 340. In the illustrated embodiment, the contacts 334 comprise a number of elongated finger-like members which extend outwardly from the base portion 332. Typically, the contacts 334 are formed in opposing rows with a gap being formed between the rows of contacts 334. The contacts 334 are formed of a conductive material and preferably, the contacts 334 are formed of a solderable material which aides in the soldering of the first electronic device 330 to the second electronic device 340, as will be described in greater detail hereinafter. This type of contact 334 is also referred to as a solder tail based upon its physical appearance and its material characteristics.

The illustrated first electronic device 330 is referred to as a straddle mount device because the spaced rows of contacts 334 and the base portion 332 resemble a straddle structure. The first electronic device 330 is mounted to the second electronic device 340 by receiving the second electronic device 340 within the gap formed between the contacts 334. Preferably, the second electronic device 340 comprises a printed circuit board having a first surface 342 and an opposing second surface 344. The second electronic device 340 also has a predetermined number of surface mount contact pads 350 formed on each of the first and second surfaces 342, 344. These contact pads 350 provide contact surfaces where an electrical connection is made between the first and second electronic devices 330, 340 through the contacts 334 and the contacts pads 350. The contact pads 350 are therefore spaced along the second electronic device 340 in a complementary manner relative to the spacing of the contacts 334 so that when the first and second electronic devices 330, 340 mate with one another, the contacts 334 and contact pads 350 engage one another.

After the first electronic device 330 has been properly positioned relative to the second electronic device 340 such that the contacts 334 engage the contact pads 350, one or more wafers 300 are brought into contact with the second electronic device 340 as shown in FIG. 12. FIG. 12 illustrates a pair of wafers 300 being disposed against the contacts 334 of the first electronic device 330. Generally for each row of contacts 334, there will be one complementary wafer 300 used for soldering the first and second electronic devices 330, 340 to one another. More specifically, one wafer 300 is disposed against one row of contact 334 and another wafer 300 is disposed against the other row of contacts 334. When the wafers 300 are properly disposed against the contacts 334, the solder segments 135 are brought into contact with these contacts 334. In other words, one or more solder segments 135 seats against an outer surface 335 of one contact 334 and provides solder material for the soldering of the each contact 334 to one contact pad 350. In the illustrated embodiment, two solder segments 135 are provided for each contact 334. These two solder segments 135 when heated serve to solder one contact 334 to one contact pad 350. As with the other embodiments, by dividing the solder length 130 into solder segments 135, the amount of the solder material which is applied for the soldering of one contact 334 to one contact pad 350 may be controlled. This reduces or eliminates the risk of having a single solder mass form and extend across the surfaces of the first and second electronic devices 330, 340.

Because the contacts 334 are preferably formed of a solderable material, the heat applied by the solder segments 135 and the reflowing action of the solder segments 135 themselves provide an effective solder connection between the contact 334 and the contact pad 350. This results in a secure electrical connection being formed between the first electronic device 330 and the second electronic device 340. Depending upon the specific application, the wafer 300 may or may not be removed from the first electronic device 330 during or after the reflowing of the solder material. FIG. 13 illustrates the instance where the wafer 300 has been removed leaving behind the contacts 334 securely soldered to the respective contact pads 350.

While the embodiment shown in FIGS. 9 through 13 illustrates the wafer 300 separate from the first electronic device 330, it is within the scope of the present invention that the first electronic device 330 may be designed so that the wafer 300 is incorporated therein or coupled thereto prior to attachment to the second electronic device 360 . In one embodiment, the first electronic device 330, e.g., a straddle mount connector, is directly attached to the second electronic device 340 without using a separate wafer 300. Instead the first electronic device 330 has the wafer 300 formed as part thereof with each contact 334 having one more associated solder segments 135. The first and second electronic devices 330, 340 are securely attached to one another by simply inserting the second electronic device 340 between the contacts 334 so that the contacts 334 seat against the conductive pads 350 of the second electronic device 340. Heating action on the solder segments 135 causes reflowing of the solder material resulting in the contacts 334 being securely attached to the contact pads 350.

It will be appreciated that instead of being integrally formed with the first electronic device 330 (or first electronic device 150), the wafer 300 (or wafer 100) may be attached to the respective first electronic device by any number of techniques. For example, the wafer may have locking features which cooperate with complementary locking features provided on the first electronic device so as to securely attach the wafer to the first electronic device. The first electronic device may be marketed and distributed this way, namely with the wafer being attached and preferably detachably attached to the first electronic device to form an assembly. The assembly is then coupled to the respective second electronic device 160, 340 and then heated to cause the solder material to reflow and electrically connect the respective components.

The embodiment illustrated in FIGS. 9 and 10 provides an attractive alternative to using a ball grid array type device for surface mount lead type devices. As is known, ball grid array type devices generally comprise connector devices which have surface mountable ball grid arrays. The ball grid array is in the form of a plurality of solder balls arranged across an outer surface of the connector according to any number of patterns. One typical arrangement is for the solder balls to be arranged in a number of rows and columns. Upon heating, the solder balls reflow and create a soldering surface for securely attaching the connector device to another device such as a planar pad of a printed circuit board.

Wafer 300 offers several advantages over using a ball grid array type connector. First, the formation of the plurality of distinctly arranged solder balls is not a simple task and requires a significant amount of time and skill. Thus, ball grid array type connectors are usually costly because of the time and skill required to manufacture such connectors. In contrast, the wafer 300 of the present invention offers improved reliability with significantly lower manufacturing and raw material costs.

FIG. 14 illustrates yet another wafer 400 for use in soldering one electronic device to another electronic device. The wafer 400 is similar to the device 300 with the one difference being that the solder material is applied to both sides of the wafer 400. Thus, grooves 310 are formed on both sides of the wafer 400 so that solder segments 135 may be formed on both sides. This type of wafer 400 may be used to solder planar pads of one electronic device, such as a printed circuit board, or a ceramic wafer (not shown) to planar pads of another electronic device or other ceramic wafer (not shown). It is intended that the wafer 400 may be used in any type of connector environment where a surface mount connector is particularly suited for use.

Turning now to FIGS. 15 through 17 in which yet another wafer according to another embodiment is shown and generally indicated at 500. As with the wafers of the other embodiments, the wafer 500 is preferably formed of a non-conductive material, such as a thermoset plastic or thermoplastic. In this embodiment, the wafer 500 is intended to be used in ball grid array type applications where a first generally planar electronic device 510 is electrically connected to a second generally planar electronic device 520. In one embodiment, the first generally planar electronic device 510 has at least one first contact 512 and the second electronic device 520 has at least one second contact 522. The first contact 512 may be in the form of a planar contact pad or the like or may be a solder ball in the case of a ball grid array type package. Similarly, the at least one second contact 522 may be in the form of a planar contact pad or the like or may be a solder ball. As is known, solder ball grid array type devices have a plurality of solder balls formed on a planar surface where each solder ball is associated with one contact terminal. The solder ball is then heated after the two electronic devices are positioned relative to one another to cause reflowing of the solder material to provide an electrical connection between the two contacts 512, 522.

FIG. 15 shows the wafer 500 in partial view. The wafer 500 generally includes a first end 502 and an opposing second end (not shown) along with a first side 504 and an opposing second side 506. The wafer 500 has one or more solder segments 530 disposed within the wafer 500 according to a predetermined pattern. Generally, there will be at least one solder segment 530 for each pair of electrical contacts 512, 522. In other words, one or more solder segments 530 are used to solder the one of the first contacts 512 to one of the second contacts 522 and provide an electrical connection therebetween. In the exemplary embodiment shown in FIG. 15, each solder segment 530 is fitted into a solder opening 540 formed in the wafer 500. The solder opening 540 extends completely through the wafer 500 so that the solder segment 530 preferably extends beyond both a first surface 501 and a second surface 503, as best shown in FIG. 16. This permits one solder segment 530 to be used to provide a solder connection between the first surface 501 and the first electronic device 510 and the second surface 503 and the second electronic device 520.

The wafer 500 also has a plurality of through holes 550 formed therein. The through holes 550 are arranged and formed in the wafer 500 such that one through hole 550 intersects one end of the solder opening 540 and another through hole 550 is formed at the opposite end of the solder opening 540 in an intersecting manner. Accordingly, the solder opening 540 opens into one through hole 550 at one end and the opposing through hole 550 at the other end. In one exemplary embodiment, each through hole 550 has a first axis extending along a length thereof and each solder opening 540 has a second axis extending along a length thereof. In the illustrated embodiment, the first and second axes are substantially perpendicular to one another. Each first axis is substantially parallel to the first end 502 and substantially perpendicular to the first and second sides 504, 506, respectively. Each second axis is therefore substantially parallel to the first and second sides 504, 506 and substantially perpendicular to the first end 502.

Because the solder opening 540 extends between two spaced through holes 550, opposing platforms 560 are formed and partially defined by the solder opening 540 and the through holes 550. FIG. 16 is a cross section view taken along a line 16-16 of FIG. 15 which cuts through the platforms 560. Thus, it will be appreciated that the edges of the platforms 560 serve to retain and hold the solder segment 530 therebetween within the solder opening 540. This design permits a single solder segment 530 to be used to provide a solder connection at opposing surfaces 501, 503 of the wafer 500. It will be appreciated that the number of solder segments 530 used and therefore the number of solder openings 540 and through holes 550 which are formed in the wafer 500 will typically depend upon the given application. More specifically and according to one embodiment, one solder segment 530 is used to provide both a solder and electrical connection between one first contact 512 and one second contact 522. Thus, if there are a multitude of first and second contacts 512, 522 provided on the respective first and second electronic devices 510, 520, there were will be a corresponding number of solder segments 530.

FIG. 17 illustrates the use of the wafer 500 in electrically connecting the first and second electronic devices 510, 520. Preferably, the dimensions of the wafer 500 are such that the wafer 500 is conveniently disposed between the first and second electronic devices 510, 520 without extending therebeyond. After disposing the wafer 500 between the first and second devices and aligning the first and second contacts 512, 522 relative to one another and then aligning each solder segment 530 relative to the first and second contacts 512, 522 such that the each solder segment 530 is in contact with or proximate to both of the first and second contacts 512, 522, the solder segments 530 are heated by known techniques. The heating of the solder material causes the solder material to reflow over both the first and second contacts 512, 522. Because the solder material comprises a conductive material, an electrical connection is provided from the first electrical device 510 to the second electrical device 520 through the first and second contacts 512, 522.

As with the other embodiments, the formation of the through holes 550 serves to define distinct segments of solder material which are used in the solder and electrical connection of one first contact 512 to one second contact 522. As previously-mentioned, this advantageously prevents a single mass of solder material from being formed during the solder operation and also prevents solder starvation sites from forming within the wafer 500.

The wafer 500 thus provides an attractive method of electrically connecting a first planar device (e.g., device 510) to a second planar device (e.g., device 520) where the wafer 500 is designed to be sandwiched between these devices 510, 520 yet at the same time provide electrical connections between corresponding electrical contacts. Not only does wafer 500 find particular utility in ball grid array type applications but also in applications where one planar printed circuit board is electrically connected to another printed circuit board. It will be appreciated that the shapes and sizes of the solder segments 530, the solder opening 540, and the through holes 550 may vary according to the given application and are not critical to the practice of the present invention. Broadly, the wafer 500 comprises a member in which a single solder segment disposed therein serves to electrically connect the first device 510 disposed against the first surface 501 of the wafer to the second device 520 disposed against the second surface 503.

Turning now to FIG. 18 in which yet another embodiment of the present invention is illustrated. In the embodiment of FIG. 18, the solder-bearing features of the wafer 500 are incorporated into the first electronic device 510. A solder-bearing member 511 forms a part of the first electronic device 510 such that one or more solder segments 530 are aligned with one first contact 512 of the first electronic device 510. Similar to the wafer 500, the solder segments 530 are disposed within solder openings 540 and extend completely through the solder-bearing member 511 so as to be accessible to both opposing surfaces of the solder-bearing member 511. It will be appreciated that the solder-bearing member 511 may be a separate member such as the wafer 500 which is securely attached to the first electronic device 510 or the solder-bearing member 511 may be integrally formed with the first electronic device 510. In both instances, the solder-bearing member 511 is preferably formed of a non-conductive material, such as a thermoplastic or thermoset plastic.

In this embodiment, the one or more solder segments 530 provide an electrical pathway to one first contact 512. Each solder segment 530 includes a first portion 517 which is disposed in intimate contact with or proximate to the first contact 512 and a second portion 519 which is formed on the opposite side of the solder-bearing member 511. The second portion 519 is thus designed for positioning relative to the second contact 522 to form an electrical and solder connection therewith upon heating. By depositing one or more solder segments 530 over each first contact 512, the first electronic device 510 may be easily electrically connected to the second electronic device 520 by positioning the first electronic device 510 relative to the second electronic device 520 such that the second portions 519 are aligned with the second contacts 522. The second portions 519 may be in intimate contact with or proximate to the second contacts 522 when the first and second electronic devices 510, 520 are positioned and coupled to one another. Upon heating, the solder segments 530 reflow and provide the desired electrical connection between the first and second contacts 512, 522. More specifically, the first portion 517 reflows over the first contact 512 and the second portion 519 reflows over the second contact 522.

Now referring to FIGS. 19-21 in which a connector 600 according to another embodiment is illustrated. The connector 600 has some similarity to the connector of FIG. 8; however, there are a number of differences as discussed below. The connector 600 includes a base or substrate (body) 610 that has a first surface 612 and an opposite second surface 614. The connector 600 includes one or more contacts 620 that are arranged throughout the substrate 610 according to a predetermined pattern. For example, the contacts 620 can be arranged in rows, etc. In addition, while the contacts 620 are shown as being conductive pins, it will be appreciated that the contacts 620 are not limited to being pins but instead can be in other forms, such as conductive pads or the like.

The connector 600 includes a number of surface features 630 that are configured to hold and retain solder material, generally indicated at 640. For example, the surface features 630 can be in the form of a number of grooves, trenches, channels or recesses or depressions 630 that receive and holder a segment of solder material 640. In the illustrated embodiment, the surface feature 630 are in the form of recesses formed in the second surface 614. Each recess 630 includes a floor 632 as well as a side wall 634. The recess 630 is opened along the first surface 612.

According to the illustrated embodiment, the contacts 620 are elongated conductive pins that have a first end 622 and an opposing second end 624. The contacts 620 are disposed through openings 621 (through holes) formed in the substrate 610 however, the contacts 620 are fixed relative to the substrate 610 once they are positioned in their intended positions. The contacts 620 are axially aligned with the surface features 630 and more particularly, the contacts 620 communicate with the surface features 630 in that the through holes 621 can open into the recess 630 by being formed through the floor 632. At least the second end 624 of the pin 620 extends into the recess 630 by extending beyond the floor 632 so as to be accessible along the first surface 612. The opposite first end 622 extends beyond the second surface 614 and is accessible for use.

As with the other previous embodiments, the solder material 640 can come in any number of different forms, including but not limited to, solder balls, solder wire segments, slugs, etc. The size and shape of the solder material 640 depends upon the size and shape of the recess 630. However, it will be understood that the solder material 640 does not have to be completely contained within the recess 630 but instead, a portion of the solder material 640 can protrude from the recess 630.

As oriented in FIGS. 19-21, the first surface 612 is the bottom surface and the second surface 614 is the top surface of the connector 600.

In the illustrated embodiment, the side wall 634 is angled relative to the first surface 612 and the floor 632 and more specifically, the side wall 634 tapers outwardly in the direction from the first surface 612 to the second surface 614. Thus, the recess 630 can have a maximum width at the floor 632 and a minimum width at the first surface 612. This construction assists in holding the solder segment 640 within the recess 630 since the width (e.g., diameter) of the solder segment 640 can be greater than the opening into the recess at the first surface 612 and therefore, once the solder segment 640 is manipulated to cause it to enter the recess 630, the relative dimensions of the solder segment 640 cause it to be caught or restrained within the recess 630.

The solder segment 640 is disposed within the recess 630 such that it is retainingly held within the recess 630 and the second end 624 of the pin 620 is at least partially embedded within the solder segment 640. Since the solder material 640 is formed of a conductive material, the contact between the second end 624 and the solder material 640 permit an electrical pathway to be formed to another conductive member that is brought into contact with the solder segment 640.

FIG. 20 illustrates the connector 600 and the contacts 620 extending outwardly beyond the second surface 614. The solder segments 640, which can be provided with or without flux, are positioned along and affiliated with the first surface 612 so that they are accessible along the first surface 612.

FIG. 21 illustrates the connector 600 being electrically connected to a second electronic device 700 that includes at least one contact 710 that is configured to mate and form an electrical connection (pathway) with the contact 620. The second electronic device 700 can come in any number of different shapes and sizes and forms so long as it is suitable for use with and complimentary to the connector 600. In the illustrated embodiment, the second electronic device 700 is in the form of a printed circuit board (PCB) that includes a substrate 702 having a substantially planar surface 704. The contact(s) 710 is provided along the planar surface 704.

In the case of a PCB, the contact 710 is typically in the form of an SMT pad 710 that is planar and lies at least substantially within the same plane as the surface 704. The pad 710 is intended to be electrically connected to the contact 620 by means of the solder segment 640. The PCB 700 is oriented relative to the connector 600 such that the contact 620 and the pad 710 are at least partially aligned with one another, e.g., the recess 630 and solder segment 640 overlie the pad 710 so that reflow of the solder segment 640 results in the solder bonding to the pad 710 and bonding the second end 624 of the contact 620 resulting in an electrical connection (conductive pathway) being formed between the contact 620 and the pad 710.

It will be appreciated that the pin 610 does not have to be in direct contact with the pad 710 but instead, and as illustrated, the second end 624 of the pin 620 can be slightly displaced from the pad 710. An electrical connection still results since the reflowed solder segment 640 effectively creates a conductive bridge between the pad 710 and the pin 620. A sufficient length of the pin 620 should be embedded within the reflowed solder segment 640 to create a robust electrical connection between the pad 710 and the pin 620, and thereby between the PCB 700 and the connector 600.

As illustrated, when the connector 600 and the second electronic device 700 mate together, the first surface 612 and the surface 704 are oriented next to one another and can be intimately touching one another.

Reflow of the solder segment 640 occurs by traditional techniques, e.g., application of heat, as described above.

Various embodiments of the present invention thus provides a wafer designed to carry solder material, whereupon heating and placement of the wafer relative to the first and second electronic devices, the solder material acts to securely attach a first contact of the first electronic device to a second contact of the second electronic device. Advantageously, the wafer may be used in a variety of settings including through hole electronic devices and also surface mount applications. The wafer has a simple yet effective design with increased application potential relative to conventional connecting devices.

Although a preferred embodiment has been disclosed for illustrative purposes, those skilled in the art will appreciate that many additions, modifications and substitutions are possible without departing from the scope and spirit of the invention. 

1. An electrical connector for electrical connection to a second electronic device having at least one second contact comprising: a substrate having a first surface and an opposing second surface, with a recess being formed in the first surface; a first contact securely coupled to the substrate and having a first portion extending at least partially into the recess; and a mass of solder material retainiagly held in the recess such that the first portion of the first contact is in contact with the solder material, the first surface being for placement against the second electronic device such that the first and second contacts are aligned and whereupon heating of the mass of solder material, the first and second contacts are securely attached to one another and form an electrical pathway therebetween.
 2. The electrical connector of claim 1, wherein the substrate comprises a block with first surface being a bottom surface thereof and the second surfacing being the top surface thereof.
 3. The electrical connector of claim 1, wherein the first contact comprises a conductive pin and the first portion comprises a first end of the pin, the pin extending through the substrate to the second surface where a length of the pin extends beyond the second surface.
 4. The electrical connector of claim 3, where the first end of the pin extends beyond a floor of the recess and is at least partially embedded into the mass of solder material.
 5. The electrical connector of claim 4, wherein the first end of the pin terminates prior to an opening of the recess along the first surface.
 6. The electrical connector of claim 1, wherein the mass of solder material is selected from the group consisting of a solder ball, a segment of solder wire, a solder slug, and a solder block.
 7. The electrical connector of claim 1, wherein the recess includes a floor through which the first contact extends.
 8. The electrical connector of claim 7, wherein an opening to the recess is defined along the first surface, with a width of the opening being less than a width of the floor resulting in the mass of solder material being captured within the recess.
 9. The electrical connector of claim 1, wherein there is a plurality of first contacts and a plurality of recesses, both of which are arranged according to a predetermined pattern.
 10. The electrical connector of claim 9, wherein there is a space formed between each recess along the first surface so that each recess is separate from the others.
 11. A combination of electrical components comprising: an electrical connector comprising: a substrate having a first surface and an opposing second surface, with a recess being formed in the first surface; a first contact securely coupled to the substrate and having a first portion extending at least partially into the recess; and a mass of solder material retainingly held in the recess such that the first portion of the first contact is in contact with the solder material; and an electronic device having a second contact and a surface that faces the first surface of the substrate, the first and second contacts being aligned with one another and whereupon heating of the mass of solder material, the first and second contacts are securely attached to one another and form an electrical pathway therebetween.
 12. The combination of claim 11, wherein the first contact comprises a conductive pin and the first portion comprises a first end of the pin, the pin extending through the substrate to the second surface where a length of the pin extends beyond the second surface.
 13. The combination of claim 12, where the first end of the pin extends beyond a floor of the recess and is at least partially embedded into the mass of solder material.
 14. The combination of claim 13, wherein the first end of the pin terminates prior to an opening of the recess along the first surface.
 15. The combination of claim 11, wherein the mass of solder material is selected from the group consisting of a solder ball, a segment of solder wire, a solder slug, and a solder block.
 16. The combination of claim 11, wherein the recess includes a floor through which the first contact extends.
 17. The combination of claim 16, wherein an opening to the recess is defined along the first surface, with a width of the opening being less than a width of the floor resulting in the mass of solder material being captured within the recess.
 18. The combination of claim 11, wherein the electronic device comprises a printed circuit board (PCB) and the second contact comprises a contact pad formed along the surface thereof.
 19. The combination of claim 18, wherein the surface of the PCB is a planar surface that seats against the first surface of the connector.
 20. The combination of claim 11, wherein the reflowed mass of solder material defines a conductive bridge between the first contact and the second contact.
 21. The combination of claim 18, wherein the pin overlies the pad and reflow of the mass of solder material results in a conductive bridge being formed between the pin and the pad.
 22. The combination of claim 18, wherein the pin is in contact with the pad after reflow of the mass of solder material. 